Fix Air Distribution Leaks
Air leaks can be a significant source of wasted energy. A typical plant that has not been well maintained could have a leak rate from 20 percent to 50 percent of total compressed air production capacity. Leak repair and maintenance can reduce this number to less than 10 percent. Overall, fixing leaks in a compressed air system is projected to reduce annual energy consumption by 20 percent.
Install Equipment Air Shutoffs
Install a simple solenoid valve so that equipment can be turned off when it is no longer using compressed air. Check compressed air distribution systems when equipment has been reconfigured to ensure no air is flowing to unused equipment or obsolete parts of the compressed air distribution system.
Clean Pipeline Filters
Blocked pipeline filters increase pressure drop. Keep the compressor and intercooling surfaces clean and foul-free by inspecting and periodically cleaning filters. Use filters with just a one pound per square inch (psi) pressure drop. The payback period for filter cleaning is usually less than two years. Fixing improperly operating filters will also prevent contaminants from entering into tools, which causes them to wear out prematurely.
Monitor Compressed Air Systems
Proper monitoring will help identify blockages and fouling that degrade energy efficiency. Routine monitoring should include:
- Pressure gauges on each receiver or main branch line
- Differential gauges across dryers and filters
- Temperature gauges on compressor and its cooling system
- Flow meters that measure the air used quantity
- Dew-point temperature gauges to monitor air dryer effectiveness
- Kilowatt-hour and hours-run meters on the compressor drive.
Use Compressed Air Mindfully
Compressed air is one of the least energy-efficient systems in an industrial plant because of the amount of energy required for compression and distribution. If compressed air is used, it should be at the minimum quantity for the shortest possible time, and it should be constantly monitored and reweighed against alternatives.
Use Lowest Pressure Levels
Try to use the lowest possible pressure level to operate the system to save energy and money.
Source: energystar.gov and Business Energy Advisor.